Method and apparatus for making form-in-place gaskets

ABSTRACT

An apparatus for making hollow, form-in-place gaskets is disclosed. The apparatus includes a nozzle and a forming surface. The nozzle comprises an extrusion orifice for extruding a gasket onto the forming surface. The apparatus further includes means for the nozzle to separately communicate with an air supply and a liquid elastomer supply. The nozzle configuration maintains the separation between the supplied air and the supplied liquid elastomer proximate to the extrusion orifice.

BACKGROUND OF THE INVENTION

Gaskets form a seal that forgives an imperfect alignment between matingsurfaces. Specifically, gaskets fill a space between the matingsurfaces. In this way, gaskets may be used to prevent liquid, dust, orgas from entering a protected space between the two mating surfaces.Gaskets may be formed independent of the surfaces, and attached ashardened material to the surfaces. Alternatively, gaskets may be formed,or dispensed, directly onto one of the mating surfaces, and cured on themating surface. In this case, a second mating surface compresses to thefirst mating surface-gasket combination to form the seal. This directdispensing, or “Form-In-Place” gasket manufacturing, addresses labor andinventory concerns associated with forming gaskets independent of actualuse. Further, “Form-in-Place” gasket shapes support a variety of gasketuses. Accordingly, gaskets may be formed-in-place, and integral to use,to support business needs.

SUMMARY OF THE PRESENT INVENTION

Various exemplary embodiments of the present disclosure may demonstrateone or more of the invention features. Other features and advantages ofthis invention will become apparent from the following detaileddescription of the presently preferred embodiment of the invention,taken in conjunction with the accompanying drawings.

In accordance with an exemplary embodiment, an apparatus for makinghollow, form-in-place gaskets includes a nozzle and a forming surface.The nozzle comprises an extrusion orifice. The apparatus furtherincludes an air supply means and a liquid elastomer supply means. Thenozzle communicates with the air supply means and the liquid elastomersupply means. Specifically, the nozzle maintains a separation ofsupplied air and supplied liquid elastomer proximate to the extrusionorifice.

In accordance with a further exemplary embodiment, a method of makinghollow, form-in-place gaskets includes supplying liquid elastomercompound to an extruding means. The method further includes supplyinglow pressure air to the extruding means and substantially simultaneouslyextruding the liquid elastomer compound and the low pressure air throughthe extruding means. The method even further includes forming a hollow,liquid elastomer bead and dispensing the bead onto a forming surface.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the present disclosure or claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings referenced herein are incorporated in and form part of thespecification. The drawings illustrate one or more exemplary embodimentsof the present disclosure and together with the description serve toexplain various principles and operations. Implications that thedrawings illustrate all embodiments of the invention are not to be made.

FIG. 1 illustrates a front view of an exemplary embodiment of anapparatus for making a form-in-place hollow gasket in accordance withthe present disclosure.

FIG. 2 illustrates a cross-sectional view of an exemplary nozzle.

FIG. 3 illustrates a perspective view of an exemplary air regulationsystem.

FIG. 4 illustrates a perspective view of an orthogonal extruding nozzle.

FIG. 5 illustrates a bottom view of an orthogonal extruding nozzle.

FIG. 6 illustrates a perspective view of a parallel extruding nozzle.

FIG. 7 illustrates a perspective view of an embodiment of a parallelextruding nozzle.

FIG. 8 illustrates a perspective view of an embodiment of a rotator ofthe present disclosure in a first position.

FIG. 9 illustrates a perspective view of an embodiment of a rotator ofthe present disclosure in a second position.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to various exemplary embodiments ofthe present disclosure, examples of which are illustrated in theaccompanying drawings.

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the figures herein,may be arranged and designed in a wide variety of differentconfigurations. Thus, the following detailed description of theembodiments of the apparatus and method of the present invention, aspresented in the figures, is not intended to limit the scope of theinvention, as claimed, but is merely representative of selectedembodiments of the invention.

Reference throughout this specification to “a select embodiment,” “oneembodiment,” or “an embodiment” means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearance of the phrases “a select embodiment,” “in one embodiment,” or“in an embodiment” in various places throughout this specification arenot necessarily referring to the same embodiment.

Features, structure, or characteristics described herein may be combinedin any suitable manner in one or more embodiments. One skilled in therelevant art will recognize, however, that the invention may bepracticed without one or more of the specific details, or with othermethods, components, or materials. In other instances, well-knownmaterials or processes are not shown or described in detail to avoidobscuring aspects of the invention. The following description, whichshows by way of illustration the specific embodiment in which theinvention may be practiced, is intended only by way of example. That is,the following description simply illustrates certain selectedembodiments of apparatus and methods that are consistent with theinvention as claimed herein. It is to be understood that otherembodiments may be utilized because structural changes may be madewithout departing from the scope of the present invention.

“Form-In-Place” gasket manufacturing directly dispenses gaskets onto amating surface, where the gasket cures. A second mating surfacecompresses to the first mating surface-gasket combination to create theseal. Gaskets may be formed in place as polymer beads. The polymer beaddeposited on a mating surface protects a final shape of an areasurrounded by the gasket seal. In non-limiting exemplary embodiments ofthe present disclosure, polymer materials may be thixotropic. In someembodiments, for example, the polymer may comprise urethane acrylates orsilicone. Those of ordinary skill in the art will appreciate thatgaskets comprising extruded, or dispensed silicone, have long lastingtemperature resistant properties. Silicone gaskets are an affordableoption for high or low temperature application. The present econtemplates all materials supporting form-in-place gasketmanufacturing. The examples of materials provided herein are forexemplary purposes, only, and are not meant to be limiting. Accordingly,gaskets may be formed in place on a mating surface.

To enhance the uses of form-in-place gaskets, gaskets may comprisehollow shapes. Those of ordinary skill in the art will appreciate thatform-in-place hollow gaskets may provide quality attributes unrealizedby solid gaskets, such as an increase in compressibility. In an example,a hollow gasket comprising holes at both ends may act as a fluidchannel. In another example, a hollow interior may act to insulate wiresinserted into a hollow gasket. These examples are non-limiting and thepresent disclosure contemplates a variety of formed-in-place, hollowgaskets. Accordingly, ultimate gasket use may influence process variableor apparatus configuration for making a form-in-place hollow gasket.

FIG. 1 illustrates a front view of an exemplary embodiment of anapparatus for making a form-in-place hollow gasket in accordance withthe present disclosure (100). In an exemplary embodiment of the presentdisclosure, for example, material may flow from a material supply tank(120) to a nozzle (140). In an exemplary embodiment, for example, amaterial supply control valve (110) may control material flow from thematerial supply tank (120) to a rotator (130). In further exemplaryembodiments, the material supply tank (120) may supply liquid elastomer,such as silicone, to the rotator (130). As will be described hereinbelow in various exemplary embodiments of the present disclosure, therotator (130) may operationally communicate with the nozzle (140) andturn the nozzle following a desired shape on a forming surface (150). Ina non-limiting exemplary embodiment of the present disclosure, thenozzle (140) may comprise an extrusion orifice (158) for dispensinghollow gaskets onto the forming surface (150). Accordingly, a materialcontrol valve (110) controls the flow of material from a material supplytank (120) to a nozzle (140), while a rotator (130) controls movement ofthe nozzle (140) following a desired shape on the forming surface (150).

In an exemplary embodiment of the present disclosure, for example,pressurized air may flow from an air supply (180) to a nozzle (140). Inanother embodiment, for example, a low pressure supply valve (178) maycontrol the flow of low pressure air from the air supply (180), andthrough an inner channel connection means (174) to the nozzle (140). Ina further exemplary embodiment, a restrictor orifice (176) may generateback pressure to a regulator (179) to address pulsations, which mayoccur at an extrusion orifice (158). In this way, the restrictor orifice(176), for example, may address a flexing of a hollow, extruded shape.Accordingly, an inner channel connection means (174) may providelow-pressure air flow from the air supply (180) to the nozzle (140).

In another exemplary embodiment of the present disclosure, for example,a high pressure supply valve (172) may control high pressure air to thenozzle (140). In a non-limiting exemplary embodiment of the presentdisclosure, the high pressure air may support cleaning the nozzle (140),including the extrusion orifice (158), once a hollow gasket detachesfrom the nozzle (140). The high pressure supply valve (172) may controlthe flow of high pressure air from the air supply (180), and through theinner channel connection means (174) to the nozzle (140). Accordingly,an inner channel connection means (174) may provide high-pressure airflow from the air supply (180) to the nozzle (140).

Those of ordinary skill in the art would understand, however, that thepresent disclosure is not limited to the embodiments illustrated inFIG. 1. That is, the present disclosure contemplates various apparatusconfigurations, including various exemplary embodiments for providing,for example, liquid elastomer and pressurized air to the nozzle (140)for dispensing hollow gaskets onto the forming surface (150).

To achieve the gasket sealing use and quality attributes necessary tosupport business needs, various exemplary embodiments of the presentdisclosure contemplate forming a hollow gasket by extruding apressurized fluid substantially collinearly or concentrically withliquid elastomer through an extrusion orifice and onto a formingsurface. As used herein, the term “forming surface,” “mating surface,”“substrate,” and any variations thereof refer to any type of matingsurface. In various exemplary embodiments of the present disclosure, ahole is coaxially introduced into a center of the gasket through aninner channel and outer channel nozzle head configuration. In alternateembodiments, for example, the nozzle head may comprise alternate outerchannel or inner channel shapes, either or both of which may not have aneasily identifiable substantial center point, such as a triangularshape. Various exemplary embodiments of the present disclosurecontemplate that the inner and outer channels may function toindependently provide air and liquid elastomer proximate to theextrusion orifice, respectively. In further non-limiting exemplaryembodiments, the inner and outer channels may provide air and liquidelastomer, respectively, to the extrusion orifice in substantialcollinear or concentric formation. Accordingly, regulated pressurizedair may be supplied to the nozzle head, such that liquid elastomer andthe air may be independently, or separately, extruded from the extrusionorifice onto the forming surface.

FIG. 2 illustrates a cross-sectional view of a nozzle (200). In anexemplary embodiment, a connection means (210) may connect a nozzle head(220) to a material supply means (not shown). In an exemplaryembodiment, for example, the material supplied may comprise liquidsilicone, or other liquid elastomer. The nozzle head (220) may comprisean outer channel (230). Various exemplary embodiments of the presentdisclosure may contemplate the outer channel (230) comprising, forexample, a reservoir (240) for capturing material flow from a materialsupply means (not shown), and for moving material to an extrusionorifice (250). In an exemplary embodiment, for example, the material mayflow from the reservoir (240) through a reservoir channel (260) to theouter channel (230) at the extrusion orifice (250). In an alternateexemplary embodiment, a plurality of reservoir channels (260) comprisesa ring and form the outer channel (230). The configuration of the outerchannel, as described herein, is not meant to limit the presentdisclosure. Accordingly, liquid elastomer material may flow from amaterial supply means to the extrusion orifice (250) of the nozzle head(220) via the outer channel (230).

In a further exemplary embodiment, for example, a regulated air pressureconnection means (270) may communicate with the nozzle head (220) tosupply pressurized air to the extrusion orifice (250). In an exemplaryembodiment of the present disclosure, the regulated air pressureconnection means (270) operationally connects a pressurized air source(not shown) to an inner channel (280) of the nozzle head (220). In anexemplary embodiment of the present disclosure, the positioning of theinner channel (280) and the outer channel (230) within the nozzle head(220) may maintain a separation between the supplied pressurized air andthe supplied liquid elastomer. Those of ordinary skill in the art wouldunderstand, however, that the location of the regulated air pressureconnection means (270) in view of the nozzle head (220) is exemplaryonly and that the regulated air pressure connection means (270) inaccordance with the present disclosure may have alternate positions.Accordingly, pressurized air may flow from a regulated air pressuremeans (not shown) to the extrusion orifice (250) of the nozzle head(220) via the inner channel (280).

In non-limiting exemplary embodiments of the present disclosure, theouter channel (230) and the inner channel (280) may be substantiallycollinear or concentric at the extrusion orifice (250). In a furtherexemplary embodiment, the outer channel (230) and the inner channel(280) may be substantially coincident, or in planar communication, atthe extrusion orifice (250). That is, the outer channel (230) and theinner channel (280) may end, or have exits, together at the extrusionorifice (250). In an exemplary embodiment of the present disclosure,having the outer channel (230) and the inner channel (280) substantiallycoincident at the extrusion orifice (250) may support substantiallysimultaneous extrusion of, for example, liquid elastomer and pressurizedair at the extrusion orifice (250). In alternative embodiments, theouter channel (230) and the inner channel (280) may be substantiallycoincident proximate to, preceding, or subsequent to the extrusionorifice (250). The exemplary embodiments of a nozzle configurationprovided herein in the present disclosure are non-limiting, and thepresent disclosure contemplates a variety of nozzle head shapes andconfigurations. Accordingly, a nozzle head (220) communicates with aliquid elastomer supply means and a regulated air supply means to supplyliquid elastomer to the outer channel (230) and pressurized air to theinner channel (270) of the nozzle head (220) proximate to the extrusionorifice.

In various exemplary embodiments of the present invention, pressurizedair is presented through the inner channel to the substantial center ofthe hollow gasket to fill the hole created by the outer channel. Withthat in mind, for example, the pressurized air may maintain thestructural integrity of the gasket walls at the extrusion orifice. Invarious further embodiments, for example, the gasket may be slightlyinflated, when compared to the gasket size created at the extrusionorifice. As a result, the walls of the gasket may become thinner, thegasket may become softer, and the height of the gasket, also known asthe first point of contact, may increase. Various exemplary embodimentsof the present invention contemplate that the thinning of the gasketwalls may create additional tension on the gasket surface. In doing so,for example, the pressurized air at the extrusion orifice may supportthe hollow gasket form. Accordingly, regulated pressurized air may besupplied through the inner channel to the extrusion orifice to maintainquality attributes of the hollow gasket extruded onto a forming surface.

In an exemplary embodiment, the air is supplied to the inner channel ata very low pressure. In another exemplary embodiment, the air suppliedis low pressurized air. In a further exemplary embodiment, the airpressure supplied to the inner nozzle is pressurized to support adesired surface tension of the liquid polymer forming the hollow gasketstructure. Those of ordinary skill in the art will understand, however,that these pressures are provided for exemplary purposes, and thatpressures in accordance with the present disclosure may be greater orless than the exemplary pressures provided herein. Accordingly, airsupplied to the inner channel of the nozzle is regulated to accommodateair pressure requirements supporting a desired configuration of thehollow gasket.

FIG. 3 illustrates a perspective view of an exemplary air regulationsystem (300). The air regulation system (300) controls the pressure ofair provided to the inner channel discussed herein above in FIG. 2. Alow pressure air supply inlet (310) communicates with a first air supply(not shown) to provide air to the air regulation system (300). The airmay be supplied at a desired pressure to the inlet (310). In anexemplary embodiment, the provided air is processed through a regulator(320). In an embodiment, the regulator (320) may be an electronicpressure regulator. In that case, pressure sensors may be built into theelectronic pressure regulators. To achieve the desired air pressure,various exemplary embodiments of the present disclosure contemplatedifferent configurations of the regulator (320). To that end, those ofordinary skill in the art will understand that an electronic pressureregulator is described for exemplary purposes, and is not meant to belimiting. A connection means (330) connects the regulator (320) to afirst valve (340). In an embodiment, the first valve (340) may be aprocess solenoid. In an exemplary embodiment, which is not meant to belimiting, the first valve (340) may connect to an inner channelconnection means (360) through a second connection means (350). In thisway, the exemplary process solenoid may control low pressure airprovided to the center of the forming gasket, as the gasket may form atthe extrusion orifice. Accordingly, air provided through an air supplyinlet (310) may be pressurized, and the air flow to the inner channelmay be controlled.

As described herein above, in exemplary embodiments contemplated by thecurrent disclosure, the second connection (350) may connect the firstvalve (340) to an inner channel connection means (360). In an exemplaryembodiment, which is not meant to be limiting, the inner channelconnection means (360) may comprise a T-junction, comprising an innerchannel connector (370). In a further embodiment, the inner channelconnector (370) communicates with an inner channel, as described hereinin FIG. 2. Accordingly, an inner channel connection means (360) connectsthe first valve (340) to the inner channel of the nozzle to providepressurized air to the inner channel of the nozzle.

As described herein above, in an exemplary embodiment, the inner channelconnection means (360) comprises a T-junction. For example, in variousexemplary embodiments of the present disclosure, the T-junctionconfiguration may allow the air regulation system (300) to supply, atleast, a plurality of air pressures to the inner channel of the nozzle.In exemplary embodiments described herein above, the T-junction maysupply low pressure air to the inner channel of the nozzle to supportforming a hollow cavity in gasket. In a further exemplary embodiment,the T-junction may additionally supply high pressure air to the innerchannel of the nozzle to clean the nozzle, also known as a tip blow off.Those of ordinary skill in the art will understand, however, that theT-junction configuration is exemplary only and that providing low andhigh air pressure to the inner channel of the nozzle in accordance withthe present disclosure may have various configurations. Accordingly, aninner channel connection means (360) may provide both low and highpressure air to the inner channel of the nozzle.

Extruded material may clog the extrusion orifice once the gasket isformed and detached from the nozzle. In an exemplary embodiment, notmeant to limit the present disclosure, the inclusion of a high pressuresource allows for unblocking at the finish of the gasket to clean theinflating source, also known as the extrusion orifice. In an embodiment,for example, the high pressure air supply has an approximate airpressure at about 80 psi. In an exemplary embodiment, a third connectionmeans (380) may connect the inner channel connection means (360) to ahigh air pressure supply inlet (395). In an exemplary embodiment, forexample, the high air pressure supply inlet (395) may communicate with asecond valve (390). In a non-limiting exemplary embodiment, the secondvalve (390) may be a process solenoid. In an exemplary embodiment, forexample, the unblocking may occur once the gasket has been completed andprior to the formation of another gasket. In various embodiments, forexample, the first valve (340) may close and the second valve (390) mayopen to allow high pressure air to flow to the inner channel of thenozzle for cleaning. Accordingly, the second valve (390) may control airpressure to the inner channel of the nozzle for cleaning.

The exemplary regulator (320) of the present disclosure described inexamples herein above may induce pulsations at the extrusion orificebefore or after extrusion of the hollow gasket onto the forming surface.In some cases, turbulence, like pulsations, may ultimately collapse theextruded hollow gasket. A restrictor may address this turbulence. In anexemplary embodiment, for example, a restrictor (not shown) may beprovided in communication with the pressure regulator (320). In anembodiment not meant to be limiting, the restrictor may control air flowbetween the low pressure air supply inlet (310) and the extrusionorifice. In this exemplary embodiment, a resulting backpressure from theextrusion orifice may mitigate a tendency of the regulator (320), suchas an electronic pressure regulator, to induce pulsation. Accordingly,an air regulation system (300) may include a restrictor to address, forexample, expansion and contraction, or pulsation, induced on a hollowgasket at an extrusion orifice by the regulator (320) during theformation of the gasket.

In an exemplary embodiment, for example, a restrictor (not shown) may beembedded within the second connection means (350), which, as discussedherein above, may connect the first valve (340) to the inner channelconnection means (360). In a further exemplary embodiment, therestrictor (not shown) may comprise a restrictor orifice embedded in thesecond connection means (350). Accordingly, a restrictor incommunication with the first valve (340) controlling low pressure airflow to the inner channel of the nozzle provides a means to addresspulsations induced on the hollow gasket before or after extrusion fromthe extrusion orifice onto a forming surface.

Form-in-place gasket manufacturing may consider gasket qualityvariables, such as shape, compressibility, and height. In variousembodiments of the present disclosure, a form-in-place hollow gasketcomprises a tubular, oval, or triangular shape, with a hollow interior,or cavity, surrounded by an elastomer exterior. A nozzle may beconfigured to represent the desired hollow gasket shape. Further, in anexemplary embodiment, the nozzle may be configured to support differentconfigurations relative to the substrate, or forming surface. Those ofordinary skill in the art will understand, however, that the presentdisclosure is not limited to such embodiments, but contemplate varioushollow gasket shapes and dimensions supporting a wide variety of hollowgasket applications. Accordingly, quality variables may influenceprocess variables or apparatus configuration for making a form-in-placehollow gasket.

In various exemplary embodiments of the present disclosure, for example,the nozzle may extrude a tubular, hollow gasket orthogonal to theforming surface. FIG. 4 illustrates a perspective view of an orthogonalextruding nozzle (400). In an exemplary embodiment, a connection means(410) may connect a nozzle head (420) to an elastomer supply means (notshown). In an exemplary embodiment, for example, the nozzle head (420)may comprise a first side (430), a second side (432), a third side(434), a fourth side (436), a top side (440) and a bottom side (450). Ina further embodiment, for example, the first side (430) may be paralleland planar to the third side (434), and perpendicular and planar to thesecond and fourth sides, (432) and (436), respectively. Similarly, thesecond side (432) may be parallel and planar to the fourth side (436),and perpendicular and planar to the first and third sides (430) and(434), respectively. Further, in an exemplary embodiment, the top side(440) may be parallel and planar to the bottom side (450). In a furtherexemplary embodiment, for example, a regulated air pressure connectionmeans (460) may communicate with the fourth side (436). Those ofordinary skill in the art would understand, however, that the locationof the regulated air pressure connection means (460) in view of thenozzle head (420) is exemplary only, and that the regulated air pressureconnection means (460) in accordance with the present disclosure mayhave alternate positions. These examples of a nozzle head configurationare non-limiting and the present disclosure contemplates a variety ofnozzle head shapes and configurations. Accordingly, a nozzle head (420)communicates with a liquid elastomer supply means and a regulated airsupply means.

The nozzle head (420) may process the liquid elastomer and pressurizedair, as described herein above, to an orifice arm (470). In an exemplaryembodiment, for example, the orifice arm (470) may communicate with thebottom side (450), extending outward from the bottom side (450). In anexemplary embodiment, for example, the orifice arm (470) may comprise anextrusion orifice (480). Liquid elastomer and pressurized air move tothe extrusion orifice (480) in the outer channel and inner channel,respectively, as described herein above, through the nozzle head (420).In an exemplary embodiment of the present disclosure, the nozzle headmay extrude the liquid elastomer and pressurized air substantiallycollinearly or concentrically through the extrusion orifice (480).Accordingly, an orthogonal extruding nozzle (400) moves liquid elastomerand pressurized air through an orifice arm (480) and extrudes the liquidelastomer and pressurized air through an extrusion orifice (480) andonto a forming surface.

FIG. 5 illustrates a detailed drawing of the “A” portion of FIG. 4, thatis, a bottom view of an orthogonal extruding nozzle (500). As describedherein above, and in exemplary embodiments of the present invention, anozzle head (520) may comprise an orifice arm (570). In furtherembodiments, for example, the orifice arm (570) may communicate with abottom side (550) of the nozzle head (520). In an exemplary embodiment,for example, the orifice arm (570) may comprise an extrusion orifice(580), which may comprise an inner channel (552) and an outer channel(554). Various embodiments of the present disclosure contemplate theinner channel (552) in substantially collinear or concentriccommunication with the outer channel (554). In further exemplaryembodiments, the inner channel (552) and the outer channel (554) may besubstantially coincident, that is, in planar communication, at theextrusion orifice (570). In alternate exemplary embodiments, the innerchannel (552) and outer channel (554) may be coincident proximate to theextrusion orifice (570). Accordingly, the nozzle head configuration maysupport dispensing hollow gaskets orthogonal to the forming surface.

In various exemplary embodiments of the present disclosure, for example,the nozzle may extrude a hollow gasket parallel to the forming surface.FIG. 6 illustrates a perspective view of a parallel extruding nozzle(600). In an exemplary embodiment, a connection means (610) connects anozzle head (620) to an elastomer supply means (not shown). In anexemplary embodiment, for example, the nozzle head (620) may comprise afirst side (630), a second side (632), a third side (634), a fourth side(636), a top side (640) and a bottom side (650). In a furtherembodiment, for example, the first side (630) may be parallel and planarto the third side (634), and perpendicular and planar to the second andfourth sides, (632) and (636), respectively. Similarly, the second side(632) may be parallel and planar to the fourth side (636), andperpendicular and planar to the first and third sides (630) and (634),respectively. Further, in an exemplary embodiment, the top side (640)may be parallel and planar to the bottom side (650). In a furtherexemplary embodiment, for example, a regulated air pressure connectionmeans (660) may communicate with the fourth side (636). Those ofordinary skill in the art would understand, however, that the locationof the regulated air pressure connection means (660) in view of thenozzle head (620) is exemplary only and that the regulated air pressureconnection means (660) in accordance with the present disclosure mayhave alternate positions. These examples of a nozzle head configurationare non-limiting and the present disclosure contemplates a variety ofnozzle head shapes and configurations. Accordingly, a nozzle head (620)communicates with a liquid elastomer supply means and a regulated airsupply means.

In an exemplary embodiment, an extrusion orifice (670) comprises aninner channel (672) and an outer channel (674). In an exemplaryembodiment, not meant to limit the present disclosure, for example, theextrusion orifice (670) may further comprise an extrusion anvil (676)and an opening to a forming surface (680). As described herein above,various embodiments of the present invention contemplate the innerchannel (672) supplying regulated air to the extrusion orifice (670) andthe outer channel (674) supplying liquid elastomer to the extrusionorifice (670). In an exemplary embodiment of the present invention, forexample, the extrusion anvil (676) may comprise a triangular shape. Inthis respect, for example, the nozzle head (620) may extrude atriangular-shaped, or other possible shaped, hollow gasket, parallel toa forming surface. Those of ordinary skill in the art would understand,however, that the shape of the anvil and the resulting shape of thehollow gasket are exemplary only, and that anvils and gaskets inaccordance with the present disclosure may have various shapes andsizes. Accordingly, hollow gaskets may be extruded onto a formingsurface parallel to the surface and in varying shapes supported by anextrusion anvil (676).

FIG. 7 illustrates a perspective view of an embodiment of a parallelextruding nozzle (700). In an exemplary embodiment, a connection means(710) connects a nozzle head (720) to an elastomer supply means (notshown). In an exemplary embodiment, for example, the nozzle head (720)may comprise a first side (730), a second side (732), a third side(734), a fourth side (736), a top side (740) and a bottom side (notshown). In a further embodiment, for example, the first side (730) maybe parallel and planar to the third side (734), and perpendicular andplanar to the second and fourth sides, (732) and (736), respectively.Similarly, the second side (732) may be parallel and planar to thefourth side (736), and perpendicular and planar to the first and thirdsides (730) and (734), respectively. Further, in an exemplaryembodiment, the top side (740) may be parallel and planar to the bottomside (not shown). In a further exemplary embodiment, for example, aregulated air pressure connection means (760) may communicate with thethird side (734). Those of ordinary skill in the art would understand,however, that the location of the regulated air pressure connectionmeans (760) in view of the nozzle head (720) is exemplary only and thatthe regulated air pressure connection means (760) in accordance with thepresent disclosure may have alternate positions. These examples of anozzle head configuration are non-limiting and the present disclosurecontemplates a variety of nozzle head shapes and configurations.Accordingly, a nozzle head (720) communicates with a liquid elastomersupply means and a regulated air supply means.

In an exemplary embodiment, an extrusion orifice (770) comprises aninner channel (not shown) and an outer channel (not shown). In anexemplary embodiment, not meant to limit the present disclosure, forexample, the extrusion orifice (770) may further comprise an extrusionanvil (not shown). In an exemplary embodiment, for example, theextrusion orifice (770) comprises a triangular shape. The nozzle head(720) extrudes a hollow gasket (750) onto a forming surface (780). In anexemplary embodiment of the present invention, for example, the nozzlehead (720) may extrude a triangular-shaped, or other possible shaped,hollow gasket (750) onto the forming surface (780). Those of ordinaryskill in the art would understand, however, that the shape of theextrusion orifice (770) and the shape of the resulting hollow gasket(750) are exemplary only, and that an extrusion orifice (770) and agasket (750) in accordance with the present disclosure may have variousshapes and sizes. Accordingly, a hollow gasket (750) may be extrudedonto a forming surface (780) parallel to the surface (780) and invarying shapes.

Those of ordinary skill in the art would understand, however, that thepresent disclosure is not limited to such embodiments, as presented inFIGS. 4, 5, 6, and 7, but contemplates various extrusion orificeconfigurations, angles of extruding relative to the forming surface, andresulting gasket shapes.

A gasket may be formed in place by positioning a dispensing tip, orextrusion orifice, above a forming surface, and then moving thedispensing tip around the forming surface to produce a desired gasketpath. The desired gasket path may be described using X axis, Y axis, orZ axis coordinates, and any combination thereof. Roll, pitch, and yaware rotations about the X axis, Y axis, and Z axis, respectively. Thoseof ordinary skill in the art may refer to movement around the Z axis, oryaw, as theta. The X, Y, Z, and theta motion elements may work inconcert to produce a vector of travel for the extrusion orifice.Acceleration, velocity, and position of the moving members may beadjusted to maintain synchronization between a vector travel rate of theorifice and a gasket extrusion rate. Various embodiments of the presentdisclosure may contemplate inclusion of a theta to direct the positionof the extrusion orifice from a first position to a second position. Theuse of theta may maintain collinear stress lines of the gasket at theforming surface. In an exemplary embodiment, not meant to limit thepresent disclosure, a rotator may adjust theta, such that the extrusionorifice travels a desired dispense path. Accordingly, an extrusionorifice changes position in view of a theta motion element.

FIGS. 8 and 9 together illustrate an exemplary rotation of an extrusionorifice in accordance with various exemplary embodiments of the presentinvention. FIG. 8 illustrates an embodiment of a rotator of the presentdisclosure in a first position (800). In an exemplary embodiment, amaterial supply inlet (810) may provide material to a material supplycontrol valve (820). The material supply control valve (820) maycommunicate with a rotator (830) through a first connection (840). In anexemplary embodiment, the first connection (840) comprises a highpressure connection. As a result, in an exemplary embodiment, therotation of the rotator (830) may not influence the position of thematerial supply control valve (820). In other words, in an exemplaryembodiment, not meant to limit the present disclosure, the position ofthe material supply control valve (820) may remain fixed relative to aposition of a forming surface (870) regardless of the position of therotator (830). Accordingly, a material supply control valve (820) maycontrol the flow of liquid elastomer to the rotator (830), but thematerial supply control valve (820) does not rotate responsive torotation of the rotator (830).

In various embodiments of the present disclosure, for example, therotator (830) may communicate with a motor (850) by means of aninterconnecting rotating belt (860). In an exemplary embodiment, notmeant to limit the present disclosure, the motor (850) may identify atheta for rotation and maneuver, or rotate, the rotator (830) using theinterconnecting belt (860) in view of the theta. In an exemplaryembodiment, a second connection (880) may connect the rotator (830) to anozzle head (890). In an exemplary embodiment not meant to limit thepresent disclosure, a regulated air supply means (892) communicates witha first side (894) of the nozzle head (890). In a further exemplaryembodiment, the nozzle head (890) comprises an extrusion arm (896),which comprises an extrusion orifice (not shown). An arrow showsmovement of the nozzle head (890) in a first position relative to theforming surface (870) as the nozzle head (890) dispenses a hollow gasket(898) in a first direction (812) onto the forming surface (870).Accordingly, a nozzle head (890) may extrude a hollow gasket (898) ontoa forming surface (870) in a first direction.

FIG. 9 illustrates an embodiment of a rotator of the present disclosurein a second position (900). In an exemplary embodiment, a materialsupply inlet (910) may provide material to a material supply controlvalve (920). The material supply control valve (920) may communicatewith a rotator (930) through a first connection (940). In an exemplaryembodiment, the first connection (940) comprises a high pressureconnection. As a result, in an exemplary embodiment, the rotation of therotator (930) may not influence the position of the material supplycontrol valve (920). In other words, in an exemplary embodiment, notmeant to limit the present disclosure, the position of the materialsupply control valve (920) may remain fixed relative to a position of aforming surface (970) regardless of the position of the rotator (930).Accordingly, a material supply control valve (920) may control the flowof liquid elastomer to the rotator (930), but the material supplycontrol valve (920) does not rotate responsive to rotation of therotator (930).

In various embodiments of the present disclosure, for example, therotator (930) may communicate with a motor (950) by means of aninterconnecting rotating belt (960). In an exemplary embodiment, notmeant to limit the present disclosure, the motor (950) may identify atheta for rotation and maneuver, or rotate, the rotator (930) using theinterconnecting belt (960) in view of the theta. In an exemplaryembodiment, a second connection (980) may connect the rotator (930) to anozzle head (990). In an exemplary embodiment not meant to limit thepresent disclosure, a regulated air supply means (992) communicates witha first side (994) of the nozzle head (990). In a further exemplaryembodiment, the nozzle head (990) comprises an extrusion arm (996),which comprises an extrusion orifice (not shown). An arrow showsmovement of the nozzle head (990) in a second position relative to theforming surface (970) as the nozzle head (990) dispenses a hollow gasket(998) in a second direction (912) onto the forming surface (970). In anexemplary embodiment, for example, the nozzle head accommodates turningon the forming surface (970). In an exemplary embodiment, for example,the inclusion of a rotator (930) responsive to theta (932) may allow thehollow gasket (998) to maintain an orientation parallel to a vector oftravel. In doing so, for example, the rotated nozzle head (990) mayminimize torsion forces that would otherwise accompany a change indirection. As it would be best understood by those of ordinary skill inthe art, the torsion forces may be moved to the inside edge, or in thehollow cavity of the hollow gasket (998), before final gasket formation.As a result, for example, the torsion forces have no effect on thehollow gasket (998) formation. Accordingly, as shown by example in FIGS.8 and 9, a rotator, (830) and (930), rotates a nozzle head, (890) and(990), from a first position to a second position, and the nozzle head,(890) and (990), changes dispensing onto the forming surface (870) and(970), from a first direction to a second direction.

It is to be understood that the various embodiments shown and describedherein are to be taken as exemplary. Elements and materials, andarrangements of those elements and materials, may be substituted forthose illustrated and described herein, parts may be reversed, andcertain features of the present disclosure may be utilizedindependently, all as would be apparent to one skilled in the art afterhaving the benefit of the description herein. Changes may be made in theelements described herein without departing from the spirit and scope ofthe present disclosure and following claims, including theirequivalents.

It is to be understood that the particular embodiments set forth hereinare non-limiting, and modifications to structure, dimensions, materials,and methodologies may be made without departing from the scope of thepresent disclosure.

It is to be further understood that this description's terminology isnot intended to limit the invention. For example, spatially relativeterms, such as “front,” “back,” “top,” “bottom,” “side,” and the like,may be used to describe one element's or feature's relationship toanother element or feature as intended to connote the orientation of,for example, the extrusion head as illustrated in the figures.

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing quantities, percentages orproportions, and other numerical values used in the specification andclaims, are to be understood as being modified in all instance by theterm “about” if they are not already. That is, unless indicated to thecontrary, the numerical parameters set forth in the specification andclaims are approximations that may vary depending on the desiredproperties sought to be obtained by the present disclosure.

What is claimed is:
 1. An apparatus for making a hollow, form-in-placegasket, the apparatus comprising: a nozzle comprising an extrusionorifice; the nozzle in communication with an air supply unit and aliquid elastomer supply unit, wherein the nozzle maintains separationbetween supplied air and supplied liquid elastomer proximate to theextrusion orifice; wherein the nozzle comprises an inner channel incommunication with the air supply unit and an outer channel incommunication with the liquid elastomer supply unit; wherein the airsupply unit comprises a first valve in communication with the innerchannel, wherein the first valve controls air flow to the inner channel;wherein the air supply unit further comprises a second valve incommunication with the inner channel, wherein the first valve controlslow pressure air flow to the inner channel and the second valve controlshigh pressure air flow to the inner channel; and a forming surface. 2.The apparatus of claim 1, wherein the inner and outer channels are insubstantially collinear communication.
 3. The apparatus of claim 1,further comprising a restrictor unit in communication with the firstvalve and the inner channel.
 4. The apparatus of claim 1, wherein theextrusion orifice has an orientation relative to the forming surfaceselected from the group consisting of orthogonal and parallel.
 5. Theapparatus of claim 1, further comprising a rotator unit operativelyconnected to the extrusion orifice, wherein the rotator unit rotates theextrusion orifice from a first position to a second position.